Method and apparatus for heating and forging elongated metal blanks



May 16, 1950 2,507,817

E. ROPP ET AL METHOD AND APPARATUS FOR HEATING AND FORGING ELONGATEDMETAL BLANKS '7 Sheets-Sheet 1 Filed Dec. 9, 1947 IRWIN ROPP WILBERT S.BLACKSTONE May 16, 1950 i. ROPP ET AL 2,507,817

METHCD AND APPARATUS FOR HEATING AND FORGING ELONGATED METAL BLANKSFiled Dec. 9, 1947 '7 Sheets-Sheet 2 I32 I22 I27 55 II is 7 IRWIN ROPPWILB ERT S, BLACKSTONE May 16, 1950 l. ROPP ETAL 2,507,817

METHOD .AND APPARATUS FOR HEATING AND FORGING ELONGATED METAL BLANKSFiled Dec. 9, 1947 '7 Sheets-Sheet 3 awuam tm IRWIN ROPP WILBERT S.BLACKSTONE May 16, 1950 E. ROPP ET AL 2,507,817

METHOD AND APPARATUS FOR HEATING AND FORGING ELONGATED METAL BLANKS 7Sheets-Sheet 4 Filed Dec. 9, 1947 IRWIN ROPP WILBERT S, BLACKSTONE May16, 1950 1. ROPP ET AL 2,507,817

METHOD AND APPARATUS FOR HEATING AND FORGING ELONGATED METAL BLANKSFiled Dec. 9, 1947 7 Sheets-Sheet 5 Ill! ROPP BLACKSTONE IRWIN WILBERTS,

May 16, 1950 I. ROPP ET AL 2,507,817

METHOD AND APPARATUS FOR HEATING AND FORGING ELONGATED METAL BLANKSFiled Dec. 9, 1947 '7 Sheets-Sheet 7 5 o- K J A 3o| 206 x 280 JPWQ/MO'LIRWSN ROPP WILBERT S. BLACKSTONE fatented May 16,

UNITED STATES PATENT OFFICE METHOD AND APPARATUS FOR HEATING AND FORGINGELONGATED METAL BLANKS Irwin Ropp, New Bedford, Pa., and Wilbert S.Blackstone, Youngstown, Ohio Application December 9, 1947, Serial No.790,606

18 Claims.

:zIBgiOIls where deforming is to take place and in 10 this manner weeffect economies in the heating Qof the blanks and materially reduce thescale Floss normally incurred in metal and forging oper- ;:ations.Further, since only spaced portions of rthe blanks are heated each ofthe blanks present (at least one substantial region of cold strong steel{capable of being very rigidly gripped by clamping means in the forgingmachine whereby the durability and reliability of the operation of such.forging means is materially increased. It is accordingly a primaryobject of the invention to provide an improved method of producingforged spikes, bolts and similar articles wherein definite economies andoperational advantages are obtained through the heating of only thoseportions of the stock blanks which are to be deformed in themanufacturing process.

A more specific object of the invention is the provision of an improvedmethod and apparatus for producing railroad spikes and the like of goodquality and at a high rate of production wherein the latter advantage isobtained through the use of stock blanks each of a length sufiicient toproduce two of the articles and wherein the blanks are heated only attheir center and end portions to facilitate their retention in aclamping and pulling device while the end and center portions of theblanks are readily formed into the upset heads and pointed ends of twoarticles for each blank.

A further obu'ect of the invention is the provision of an improvedmethod and apparatus :for hot-forging railroad spikes and the likewherein the heating required for each blank is accomplished in a veryshort interval of time and is limited to those regions which are workedin the forming process whereby the formation of scale is minimized andwhereby the locally heated blanks are fed to the forging machine in aclean and bright yet strong condition to materially facilitate theforging operation. Further, the substantial elimination of scale fromthe forging apparatus is highly advantageous in insuring uninterruptedoperation of the machine over long periods of service.

a; mechanical power source.

Yet another object of our invention is the provision of an improvedspike forging and formin machine wherein a pair of completely formedspikes may be expeditiously formed from each of 5 a succession ofelongated blanks of uniform crosssection. Thus, through the employmentof an improved method and apparatus our invention enables high qualityspikes to be rapidly produced from simply formed blanks.

A further object of the invention is the provision of an improved spikeforging machine wherein an elongated stock blank is securely gripped atlongitudinally spaced points and while so gripped has both its endsupset to form the 15 heads of two spikes after which the blank isdeformed between the clamped portions and pulled apart to form thepointed end of two spikes. This arrangement makes maximum use of theparts of the machine and enables the spikes to be formed at a high rateof production.

Further, since both ends of the blank are simultaneously upset theforces opposing the upsetting operations oilset each other within theblank and consequently the gripping or clamping need not be so severe asis the case in more conventional machines.

Other objects of the invention include the provision of an improvedspike forging machine wherein all of the stock-engaging and working acomponents are assembled in depending relation to receive a stock blankfed vertically upward whereby any scale spalled ofi during the formingoperation will fall down free and clear of the operative parts of themachine. Also included a is the provision of a materially simplified yetrugged and durable machine for forming railroad spikes and the likewherein all the sequential operations necessary to be performed'on astock blank are timed through the use of a unitary A still furtherobject of the invention is the provision in apparatus for producingrailroad spikes and the like of an improved arrangement for heating theblanks, of an improved apparatus 4' for feeding blanks consecutivelyinto the heating means, and of an improved device for feeding heatedblanks into the working area of the assembled apparatus.

The above and other objects and advantages 50 of the invention willbecome apparent upon con- 88 Figure 1 is a plan view of the apparatus ofthe invention including preferred blank heating and feedingarrangements;

Figure 2 is a perspective view of the heating device of the presentinvention;

Figures 3, 4 and 5 are perspective views of the product of the machineof Figure 1 at successive stages in its operation;

Figure 6. is a horizontal section of the machine of Figure 1;

Figure 7 is a side elevation of the machine of Figure 1;

Figures 8, 9, 10 and 11 are sectional views taken respectively at linesVIII-VIII, IX-IX, XX, and XlXI of Figure 6;

Figure 12 is a plan view, on an enlarged scale of a portion of themachine of Figure 1;

Figure 13 is a side elevation of the portion of the machine illustratedin Figure 12;

Figure 14 is an enlarged fragmentary view of the device of Figure 13 andillustrates the mechanical action thereof;

Figure 15 is a time graph showing the mutual relation existing betweenthe several operations of the machine of the invention;

Figures 16. and 1'? illustrate the physical. motion of several of theimproved mechanisms Within the machine; and

Figures 18, 19 and 20 are schematic showings of a modified form of spikeforging machine con.- structed in accordance with the principles of theinvention.

Referring now to the drawing. more in detail it will be observed thatthe spike making machine proper is supported upon and contained within astructural steel weldment comprised of the base Iebeams is and H, lowerand upper cross beams l2 and i3 respectively, vertical corner beams 14and upper longitudinal beams l5. One extremely deep I-beam iii replacesthe vertical corner beams H1. at the left end of the machine as viewedin Figure 7.

A floating belt tensioner H is mounted on the upper beams is to supportan electric motor [8, power from which is transmittedthrough pulleys I9and 253 and multiple V-belts 21- to the mechanism proper which presentlywill be described in detail. An electrical switch 22 (see Figure 6) isincorporated in the machine and is arranged to successively make andbreak a suitable series of contactors (not shown) once upon each cycleof operation of the mechanism. This primarily establishes an index forthe operation of the feeding mechanism nowto be described.

Attention is directed to Figure 1 wherein the spike making machineproper has in association asupply device 23, a feeding assembly 24, aheating assembly 25 and a feed conveyor 28. A supply of suitablyprepared. elongated square steel blanks 3B are held in readiness withina feed hopper, not shown, and are fed by gravity onto a horizontallydisposed walking beam conveyor 3|. A motor 32 operates conveyor 3]continuously to keep a steady supply of blanks 3 0 traveling outwardlyof conveyor 3! and against a stop 33 where the headmost blank 3!] isheld in readiness for the next succeeding operation.

Upon the periodic operation of switch 22 a feed solenoid 34 is actuatedand through suitable linkage 35 operates to move a pusher 36 forwardlyagainst the blank 39 which is currently at rest against stop 33. Thesaid blank is thus urged forward axially into the heating assembly 25.Upon completion of its forward travel pusher 36 is caused to return toits retracted position by the timed energization of a return solenoid 31which is also under the control of switch 22 and which operates inopposition to solenoid 34 described above.

The heating assembly referred to generally by the numeral 25 is anelectrical induction heater of the intermediate frequency type which iswell known in the electrical heating art and which need not be describedin detail. Its energy is applied to each successive blank 30 as theblanks are moved forwardly into the induction loops 38, 3 9 and 40. Thepotential supplied to these loops is of such magnitude and frequencythat proper heating takes place in the encircled blank 30 in theallotted time during which it remains at rest. The first coil 38 and therear coil 40 each heat an end of the blank for the subsequent headingoperations while the center coil 39 heats the center portion of blank 30so that the subsequent forging and stretching operations at this portionmay be readily effected.

Switch 22 is energized to initiate a repetition of the feeding cycleoutlined above and the blank 3.0 which has been last heated is sentaxially forward down the roller feed conveyor 25 toward its next stationin the cycle of operation of the machine. Attention is directed toFigures 3, 4 and 5 for a graphic showing of the steps which subsequentlyoccur in operating on the previously heated blank 30.

Figure 3 shows the blank 30- after heads 42 have been forged upon. eachend thereof. The designing of these heads is beyond the purview of thepresent invention, it being obvious that the configuration thereof, willdepend largely upon the shape of forming dies used. It will be ap-.parent however, that such heads as the ones illustrated, wherein thereis a marked thickening or upsetting as at 42, may be most advantageouslyfabricatedin the machineof; the present invention. Sinceconsiderableaxial thrust must be exerted by the heading dies. upon thesquare ends of the rough blank 33 in order toforce the parent metal backupon itself and thus to swell out and form the head 42 and the upset 42,it will be. apparent that quite stringent clamping action would have tobe applied throughout the center portion of the blank 3Qif it were to beheld securely enough to resist a single-ended blow, By applying theprinciples of the. present invention it is possible tohold the blank 30witha less severe force since the opposite heads. are formedsimultaneously by oppositely directed blows of the forging, dies.

Following the heading operation the machine of our inventionprogressestopartially form the points of and to partially sever the two spikes approximately as shown in Figure 4. The, two clefts 43 and 43 extend intothe body of, the blank on opposite sides thereof, to such a depththat aweb 43" of parent metal of the thickness. of, the orderof /32" is leftjoining the two halves. Immediately upon withdrawal of the severing diesthe two halves of the bar are drawn apart as indicated and the joiningweb 43 is drawn out extremely thin before it finally ruptures. The sharpedge 44 thus produced constitutes a relatively sharp penetrating pointuponthe finished spike.

In. further disclosing the mechanical details of the machine of theinvention attention is directed to Figures 1 and 7 wherein it will beobserved that the pulley 20 mentioned supra is carried upon a laterallyextending driven shaft 45 which projects from a worm gear reducer unit46. A continuation 45' of shaft 45- extends toward a second gear reducer41 whose shaft 48 is in turn extended. toward shaft 49 of a third gearreducer 50. The several gear reducers mentioned are all secured to theunderside of one of the upper. side beams l of the machine frame.Flexible couplings 5| are used at appropriate places to. make the shafts45, 48 and 49 substantially continuous and thus to impart power to the.several gear reducers 46, 41 and 58 simultaneously. The output shafts52-, 53 and 54 of the gear reducers 46, 41 and 58, respectively, aredisposed transversely of the main machine assembly and perform variousfunctions presently to be set forth. The said output shafts all operateat the same. speed but in several directions 1. e. as indicated inFigure. '1 the shafts 52 and 53 both rotate counter-clockwise while theshaft 54 rotates clockwise. The shaft 52 serves to drive only the spikeheading mechanism and the electrical switch 2 2- and its action will bedescribed in detail below. The shafts 53 and 54, provide power for thefunction of raising, gripping, severing, drawing and ejecting theproducts and their actions together with their associated mechanicalelements, will presently be described in detail.

We have provided, upon the base beams l8 and ll, 2. pair of upwardlyextending supporting brackets 55 and upon these we mount a pair ofpillow blocks 56 which are aligned to journal a transversely disposedlifter shaft 51. As viewed in Figure 8, shaft 51 will be seen to extendto the left beyond pillow block 56 and to this extension a crank 58 isattached. The free end of crank 58 pivotally engages the lower end of alinkage bar 59, the upper end of which is slotted to afford alost-motion connection with a second crank 68. Crank 68 is secured toshaft 54 and at each rotation thereof imparts to shaft 51 a peculiarmotion consisting of a rapid clockwise rotation, a rapidcounter-clockwise return and a relatively long dwell which dwell occursas crank 60 travels freely in the slot of linkage bar 59. A pair ofdepending arms 6| are secured to the central portion of shaft 51 and tothe lower free end of arms 6| is pivotally secured the forward end of aconveyor supporting platform 62. Platform 62 has its rearward endpivoted to the lower free ends of a pair of equalizer bars 63 whoseupper ends are in turn pivotally secured to upright corner beams 14 ofthe machine frame. Extending vertically from the forward end of conveyorsupporting platform 62 and angularly braced thereupon there is provideda short length of roller conveyor 64 whose double flanged rollers 65 areadapted and aligned to receive the approaching blanks 38 as each isdelivered by feed conveyor 26. An adjustable stop 66 is attached to oneof the supporting brackets 55 and is positioned to bring the advancingbar 38 to a stop upon rollers 65. It will be apparent that as shaft 51is rotated clockwise (as observed in Figure '1) the conveyor rolls 65and the supported bar 30 will be swung to the left and raised in anarcuate path towards the next station within the machine.

To provide means for receiving and momentarily holding bar 30 as it isdelivered from rollers 65, as described above a pair of electro-magnets61 are rigidly suspended from a bridging member 68, which is in turnsupported upon the upper cross beams 13 of the machine frame. Magnets 61are provided with spaced, downwardly disposed pole pieces 69 whichcontact the blank 30 at two spaced points near its mid portion and thusthe blank is held securely and in balanced horizontal position.energized by suitable contactors within sequencing switch 22 and theyoperate to. hold blank 30 while rolls 65 are quickly retracted and whilea pair of working clamps referred to generally by the reference numeral18 secure said blank.

Clamps 18 constitute means for holding blank 38 from this stage of theprocess until all opera-N tions are completed and a pair of finishedspikes are delivered. Clamps 10 are basically constituted of a pair ofclamp beams 18 which are freely journaled at their opposite ends upontransverse shafts 53 and 54 and which each bear a complement of partsnow to be described. As both sets of clamps are alike except for thedirection of their operation, the mechanism of but one set will here bedescribed. Referring now to Figures 12 and 13 it will be clear thatclamp beam 10 is an integral beam-like member and that it is freelyjournaled upon and supported by shafts 53 and 54. Anti-friction bushings1| permit unrestrained rotation of both shafts and beam 10. is also freeto slidev axially along both shafts. Suitably contoured cam wedges 12are provided upon the inner face of beam 18' and are adapted to beengaged by complementary cam wedges 13 which are secured to cam discs14. Cam discs 14 are keyed to shafts 53, and 54, respectively, and arelocated at the exact center of the complete machine.

Upon rotation of shafts 53 and 54 the wedges 12 and 13 react to movebeam 18' outwardly from the center of the machine. Cam wedges 15, shapedsimilarly to cam wedges 12, are secured to opposite outer faces of beam10' as shown. Return cam discs Hi4 and 16 are affixed to shafts 53 and54, respectively, outwardly of the beams 18 and bear upon their innerfaces cam wedges 11 which are complementary to wedges 15. Wedges 15 and11 co-act, upon rotation of shafts 53 and 54 to return beam 18' towardthe center of the machine. Thus it will be apparent that once upon eachrotation of shafts 53 and 54 the two clamp beams 18' of the machine willmove away from each other, i. e. outwardly from the center of themachine, and will return toward each other. The speed and distance oftheir travel may be regulated by the configuration of the mutuallyoperating cam wedges 12-13 and 15-11.

Slideably attached to beam 18' and in depending relation thereto weprovide a pair of clamp blocks and 8|. The clamping action of blocks 80and 8| is initiated by the rotation of shafts 53 and 54 in the followingmanner. The cam discs 14, which are secured to shafts 53 and 54, eachare provided with a toggle operating pin 82 which is locatedeccentrically upon said discs and extends on both sides thereof in adirection parallel to shafts 53 and 54. The location of pin 82 isclearly shown in Figures 9, 10 and 11. Each of the clamp beams 10' carryclamping mechanisms which must be operated and we therefore make pins 82of sufficient length that they may always reach beams 10 whether saidbeams are closely or widely spaced from each other.

To the overhanging end portions 83 of beams 18 there is pivotallysecured a toggle operating yoke 84 which is best seen in Figure 14.Pivot bolt 85 provides a fixed point for the rotation of yoke 84, theopposite end of which is pivoted to a toggle link 86 by a pin 81. Theopposite end of toggle link 86 is secured to clamp block 88 by a pivotpin 88. When the entire toggle assembly Magnets 61 are cycliclyv isarranged as shown in solid lines in Figure 14 the pin 81 is raised abovethe center of pin 88, the upper edge of link 86 is brought to restagainst a stop surface 89 and the block 80 is moved to the extreme leftlimit of its travel where it co-acts with mating clamp block 8! tosecure blank 30 in place. The operation of the present toggle clampingassembly will be seen to make full use of the advantages accruing fromthe employment of such over-centering devices. When toggle operatingyoke 84 is depressed, allowing pin 81 to assume the position indicatedin broken lines, clamp blocks 80 and 8I will be retracted from theirclamping position. Power to move operating yoke 84 is supplied by toggleoperating pin 82 described above. As shaft 54 rotates, in the directionof the arrow in Figure 14, pin 82 is caused to contact the upper insidesurface 8 3 of yoke 84 and to urge it upwardly thus raising toggle pin81 and moving clamp 80 to a closed position. The relative length ofinside surface 84' provides an index of the length of time the clampmeans will secure the blank 39. As shaft 54 rotates further to the rightpin 82 leaves upper surface 8 2 and presses downwardly upon lowersurface 84 at which time toggle pin 81 is depressed and clamps 89 and 8|are opened. The length and contours of surfaces 84' and 84 arecalculated to cause clamping to endure long enough and releasing tooccur quickly enough to suit the other features of the routine ofoperation being performed.

To more efficiently secure work blank 39 the clamp blocks 80 and 8! areboth made in different manners. Block 8| is a rigid member which has agroove 90 formed in its forwardly disposed surface to receive blank 30.Groove 90 is slightly wider than blank 30 but is not so deep as tocompletely receive it. Thus a slight portion of blank 30 protrudes to bepressed by block 80. Block 80 is provided with a spring biased facemember 91 which is urged outwardly by spring 92. An adjusting block 93provides means for varying the compression of spring 92 and thus of theultimate gripping force of the entire assembly.

Each of the clamp blocks 89 and 8| are so constructed that they embraceopposite ends of blank 30 over a substantial portion of the latterslength and they are so formed that they mutually constitute a forgingdie which determines the final shape of the underside of the head 42 andof the upset portion 42 of the finished prodnot of the machine.

To provide positive means for ejecting the blank 30 from the groove 98upon the opening of clamp blocks 80 and SI there is provided a springbiased knock-out assembly referred to generally by the numeral 95. Aplate member 98 is slideably mounted upon the outer face of clamp beam10' and is free to move upon bolts 91 which are embraced by a slot 98. Atension spring 99 biases plate 96 toward the center of the clampingarea. Tension adjustment of spring 99 is possible by changing theposition of a spring clip I upon bolts IOI. A pusher bar I02 is securedto plate 96, is disposed adjacent to the clamp block 8| and is capableof expelling the bar 30 under the urging of spring 99. A retractingextension I03 is formed upon the rearward end of plate 96. Cam I04 iscontoured to engage the inner surface of extension I03 during a majorportion of the machines operating cycle and thus to hold pusher bar I02retracted, but it is provided with a sharp declivity which permitsalmost instantaneous action of the entire knock-out assembly at theproper point in the operating cycle.

Attention is now directed to Figures 10 and 11 for a consideration ofthe severing mechanism of the present invention. As was noted above abridging member 68 is provided at the center of the work area in ourmachine to support a magnet 61. We prefer to utilize this member also tosupport our cutting assembly. Upon the underside of member 68, in anarea not occupied by magnet 81, we provide a pair of shear guide blocksI05'whioh afford support for a pair of sliding shear blocks I06 and I91which confront each other from opposite sides of the location of blank39. One of a pair of shearing dies I08 is carried by each of the blocksI06 and I01 and these dies are contoured to form upon the blank 30, thetapered cleft portions 43 and as shown in Figure l. There are alsoprovided upon blocks I08 and I91, respectively, a lower restraining barI09 and an upper restraining bar I01 which mutually embrace the lowerand upper sides respectively of the blank 30 to resist deformationthereof during the action of dies Hi8. Shear blocks I09 and It? withtheir attached shearing dies and restraining bars are caused to advanceto and retract from the work blank 30 by the action of the peripheralcam surfaces of cams 14, mentioned above, upon suitable cam connectingrods I09. Wrist pins IIfi afford required flexibility in the linkagebetween blocks I06 and I91 and connecting rods I99 and removable bearingcaps I II facilitate assembly and repair of the shearing mechanism.

For considerat on of the forging hammer elements of the presentinvention attention is directed to Figures 7 and 10. W e utilize thebase beams Ill and II and the upper longitudinal beams I5 of our machineframe to ri idly secure the lower and upper ends respectively of a pairof hammer pivot rods H9 and 12!. Suitable angle brackets secure thelower ends of the rods while the upper ends are held in blocks I29.Surrounding rods I20 and I'll and freely journaled. thereupon byanti-frictic-n bearings I29 are elongated sleeves I25. Securely weldedto each of the sleeves is an upper or die supporting arm I 26 and alower or linkage pivot arm I21. A stiffening web I28 is interposedbetween arms I29 and I21, is welded to both, and adds materially to therigidity of complete hammer arms units. Upon the outer free end of eachof the arms I26 a die holder I29 is secured and it is adapted to receivea die block I39 which formed to suit the operation at hand.

To cause both of the die supporting arms I29 to act simultaneously weprovide a common drive for both and both are therefore connected to thedrive ass nibly by suitable draw links I3! each of which has an outwardfree end pivoted to a pivot arm I21 of a respective hammer assembly. Theinner ends of links I35 are pivotally connected to a cross head I32which is slideably restrained upon a raised slide rail I33. A suitablebeam and plate structure I34 supports slide rail I33 above cross beamsof the machine frame. A master drive link I35 has its one end pivoted tocross head I32 and its opposite end pivoted to the lower end of a pitmanlever I39. The fixed end of pitman I36 is pivoted to the machine frameby a pivot pin I31 and its intermediate point has pivotal connectionwith one end of a connecting link I38 through pivot pin I39. Mo-

tion is imparted to the entire hammer assembly by a crank I40 which isformed in power shaft 52 mentioned above and which has one end ofconnecting link I38 journaled upon its crank pin MI. The several linksI3I, I35, I36 and I38 have their respective pivots arranged in suchmanner that they co -act to move both die supporting arms I26 inwardlytoward work blank 30 in a comparatively rapid motion during the firstportion of their travel and to move more slowly but with much greaterforce during the final part of their travel. This arrangement will bemore clear upon consideration of Figures 16 and 17 of the drawingwherein the motions of the several parts are illustrated in variouspositions. In Figure 17 it will be apparent that as cross head I32 movesto the left from position A to B to C the angular relation between thecenterline of link I3I and the line of travel of cross head I32 becomesless acute and more nearly linear. This places the several parts inposition for most efficient transmission of the greatest mechanicaleffort. Figure 16 illustrates the advantage of the leverage actiontaking place in the vicinity of crank I40 on shaft 52. As the crank I40is rotated in the direction of the arrow and as it travels through theupper arcuate portion of its path at about the position indicated inbroken lines the leftward linear component of its speed is considerableand the motion of pivot MI and link I38 is therefore proportionallyrapid. As crank pin I4I approaches the position shown in solid lines aline passing through pivot pins I39 and MI and shaft 52 approaches astraight condition and constant torque applied to shaft 521s therebyconverted into a lateral motion of pin I39 which motion decreases inmagnitude but increases in intensity as this straight line condition isreached. Since this most forceful increment of motion in the drivelinkage occurs as the hammer arms I26 bring dies I 30 into action uponthe work blank 30, considerable advantage will be seen to accrue fromthe arrangement of the present device.

It will be observed that the structural mem bers 68, I and I26 are alldisposed about the working area of the machine in such manner that scaleor other foreign matter which may drop from the blanks 30 can in no wayinterfere with any of the moving parts of our device.

In operation the machine of the present invention will carry out theseveral steps of the spike forging process in an entirely automaticmanner. When the supply hopper, mentioned earlier, is filled withsuitably cut square bars of I steel and the motor 32 is energized tooperate walking beam conveyor 3I, the machine is in condition tofunction and the main drive motor I8 may be started to initiate thefollowing cycle of automatically sequenced operations.

As blanks 30 move in lateral procession along conveyor 3| and theleading blank of the group is brought to rest against stop 33 thesolenoid 34 will be energized by switch 22 to actuate linkage 35 andpusher 36 and to advance said leading blank into position within heatingcoils 38, 39 and 40. Energization of solenoid 31 by switch 22 willreturn pusher 35 thus allowing another bar 30 to move against stop 33.The next subsequent stroke of pusher 36 will cause a new blank 30 toadvance and eject the preceding heated blank from the heating coils andonto feed conveyor 26. As the heated blank comes the rest upon rolls ,65and against stop 66 the rotation of shaft 54 will furnish power viacrank 60, bar '59, shaft 51 and arms 6| to swing conveyor 64 upwardlyinto the work area of the machine where magnets 61, energizedmomentarily through switch 22, will attract and hold blank 30. Conveyor64 will next be retracted to its lower position and further rotation ofshafts 53 and 54 will cause cam discs '14 to rotate and bring pins s2 tobear upon closing surfaces 84' of clamp operating yokes 84. The raisingof yokes 84 will act through toggle links 86 to advance clamp blocks 60and SI to securely grip blank 36 and at this time magnets 6'! will bedeenergized. During the time that the clamp blocks and 8| have beenmoving toward their clamping position the rotation of shaft 52 has beencausing crank I40 to move levers I38, I35 and I35 to the left, oroutwardly of the machine, and to thus draw cross head I32 back and toapply tension upon draw links I3I. The attendant swinging of pivot armsI21 causes sleeves I25 to rotate and to bring die supporting arms I26inwardly toward the opposite exposed ends of blank 30. Die blocks I30upon the free ends of arms I26 are now forcibly pressed against clampblocks 80 and ill to mutually effect the heading and upsetting operationupon the ends of the heated blank 30 and thus to simultaneously form thetwo heads 42 and the upset shank portion 42 as shown in Figure 3.

Upon completion of the heading operation die blocks I30 are swungoutwardly of the machine and continued rotation of shafts 53 and 54rotate cams '14 to energize the severing mechanism for forming thepoints of the spikes. As cams l4 rotate they force the shear blocks I06and I 01 toward each other from opposite sides of blank 30 and partiallysever it, forming therein the clefts 43 and 43 of Figure 4 and leavingonly the relatively thin web 43 between their advancing faces. As camdiscs I4 further rotate and begin to retract shear blocks I05 and ill!the cam wedges 12 carried upon discs 14 commence to engage cam wedges 13which are secured to the inner faces of clamp beams 10' and to forceboth of the beams 10' away from each other along the shafts 53 and 54.Since clamps 80 and BI still retain their grip upon blank 3!! and sincea set of clamps are rigidly carried by each of the beams 10' it will beunderstood that the motion imparted by cam wedges I2 and 13 results in adrawing operation in the unsevered web 43 which drawing breaks the weband completely separates the two spikes from each other.

Further rotation of disc 14 causes pin 82 to engage the lower surfaces84 of yokes 84 and to break the toggle by depressing pivot 81 and thusto release the clamps 80 and 8| and. return them out of the work area ofthe machine. The two spikes are now each frictionally held within thegrooves of their respective dies BI and it remains for the retractingcams I04 to be turned by shaft 53 to the position where they will ceasetheir restraint upon the knock-out assemblies 95. When this occurs theextension I03 of plates 96 ride free of the cams I04 and springs 99 arefree to quickly draw plates 96 and their attached pusher bars I 02toward the right where bars I02 strike sharply against the finishedspikes to expel them from die blocks 8!. Continued rotation of shafts 53and 54 brings return cam wedges 'I'I into co-action with cam wedges 15upon the outer faces of beams I0 and causes the latter to return towardthe center of the machine where they may begin a repetition of theiroperating cycle.

The several steps of the complete cycle of operation thus far describedobviously need not all occur as independently timed actions but aretimed to overlap each other in a manner best calculated to result in thegreatest overall efliciency of the machine and the process of theinvention. By referring to Figure 15 of the draw ing one may see agraphic plotting of the relative time cycles required for the completionof the various motions. The abscissae of the graph are arranged inincrements of degrees of rotation a fixed reference point upon theshafts 52. The zero condition is taken to exist when the shaft 52 is inthe position illustrated in Figure 7, i. e. with the centers of shaft52, the crank pin MI and the pivot pin I39 lying in a straight line. Atthis time the heading die blocks l3 are in their innermost position andare about to move outwardly, severing dies I05 and Hi! are about midwayin their closing cycle, clamps 8D and ti are closed and cam wedges l2and 13 yet have about 20 to travel before they engage. The ordinates ofthe graph are arranged in increments of distance traveled. Theseincrements are not drawn to scale but rather show the proportionalmovement occurring in the several elements. The kinds of linesrepresenting the motions of the several elements will be clear in thekey accompanying Figure 15.

It should now be apparent that the machine and the process of ourinvention accomplish the objects initially set forth. Doubling of theproduction rate of the machine is achieved with an attendant economy inthe size and strength of machine parts required. The heating of workblanks is accomplished in an efficient and economical manner by the useof induction heating coils 38, 39 and 4G. The reduction in scale whichresults from this method of heating permits more trouble-free operationby excluding excessive foreign material from the working parts of themachine. The shearing and forging action performed by our severing diesI08 and the drawing action performed by our clamps 80 and 8! combine toproduce an extremely efficient and novel pointing assembly and method.The driving shafts 52, 53 and 54 and the various operating cams andcranks l2, l3, I4, 15, l! and M0, of our machine all operate in positivesynchronism and are driven from a common source of power, motor l8, andthus are prevented from becoming misadjusted in any manner. Theiroperation is at all times positive, accurate and unified. The design andarrangement of the moving parts of our machine is such that any scale orforeign debris which may adhere to the stock blanks being fed thereto isallowed to fall free of the machine and can in no way incapacitatemoving parts.

An important aspect of our invention is the heating of the stockmaterial only at the locations where forming or working of the materialwill take place in the produtcion of the article. This arrangement isparticularly advantageous in that it effects definite economies in theheating of the stock and in the reduction of scale loss, and in that itfacilitates the operation of the clamping means of the heading andsevering mechanism. As to the latter feature, it should be noted thatthe stock is clamped at a cold portion or portions which makes the tightgripping of the stock possible.

In the embodiment of the invention shown in Figures 18, 19 and 20, thestock is fed from a suitable source (a coil, for example) through theheating station 225 and through the heading and severing machine in acontinuous step-by-step manner. At each pause in the movement of thestock a localized portion of the stock is heated by the inductionheating coil 225, and it will be observed that the distance between thecenter of the heating coil and the center of the pointing and severingmechanism 208 is substantially equal to the distance between thepointing and severing mechanism and the heading or upsetting station.Thus, each spot or zone of heating of the stock serves both forfacilitating the forming of the pointed end of a spike or the like andthe forming of the head of the next succeeding spike or the like. Theadvantage of having a cold center portion of each spike is retained.

More specifically, the apparatus of Figures l8-20 comprises clampingmeans 300, 30!, carrying arms 205, and the severing tools 298, clampingdies 28%] carried by the slides 21!), and a head ing die 230' carried bythe arm 229. The machine incorporating these various elements may besimilar to the machine described above for it will be clear that withthe parts opened as in Figure 18 the stock 238 may be advancedlongitudinally to the position shown in the figure. Now the clamps 300,38! and the dies 280 may be closed and the forging die 230 applied toform the head of the spike, all as shown in Figure 19. The next step isthe closing of the cut-off dies 208 and the pullin away of the dies 28!]in the direction shown by the arrow in Figure 20 to sever the formedspike from the stock. During all these clamping and forming operationsthe stock is heated locally by the coil 225 so that the duty cycle ofthe heating means will be quite high. Immediately upon opening of theparts the stock can be advanced another spike length. If desired, we canemploy other means, as electric resistance heating, for example, inplace of the induction heating coil 225.

While we have limited the above specification to a detailed showing ofthe construction and operation of assemblies and machines for makingrailroad spikes it should be understood that the principles of theinvention are equally applicable in the manufacture of headed nails andbolts and similar articles. The specifically illustrated and describedembodiments of our invention therefore should be considered asillustrative only as obviously many changes may be mad 2 therein withoutdeparting from the spirit or scope of the invention. Reference shouldtherefore be had to the appended claims in determining the scope of theinvention.

What we claim is:

1. The method of producing spikes or the like each having an upset endwhich consists of heating a length of stock only at both end and at thecenter portion thereof, upsetting the heated ends of said stock length,and severing said length of stock at said center portion to provide apair of headed spikes or the like.

2. The method of producing spikes or the like each having an upset headand a pointed end which consists of heating a length of stock only atboth ends and at its center portion, upsetting the ends of said stocklength, reducin the crosssectional area of said stock length at saidcentrally heated location, and thereafter pulling the two opposite endportions of said stock length apart to provide two spikes or the likeeach having a headed end and a pointed end.

3. The method of producing spikes or the like each having a headed endwhich consists of applying induction heating only to th two end portionsand to the center portion of a stock length, thereafter simultaneouslyupsetting both ends of said stock length, and dividing said stock lengthat the centrally heated portion to provide two separate headed spikes orthe like.

4. The method of producing spikes or the like which consists of applyinginduction heating only to the two end portions and to the center portionof a length of stock, simultaneously upsetting both ends of said stocklength, reducing the crosssectional area of said centrally heatedportion of said stock length, and thereafter pulling said stock lengthapart with the line of severance cor:- responding with said heated andreduced center portion to provide a pair of spikes or the like eachhaving an upset head and a pointed end.

5. The method of producing spikes or the like each having an upset headwhich consists of heating only the end portions and the center portionof a length of stock, gripping said stock length at points intermediatesaid center portion and each end thereof, upsetting the ends of saidstock length while the length is so gripped and thereafter pulling saidgrip portions apart with the line of severance coinciding with saidcentrally heated portion to provide a pair of spikes or the like eachhaving an upset head.

6. The method of claim including the further step of swaging thecentrally heated portion of said stock length preparatory to saidpulling apart operation whereby said spikes or the like are providedwith tapering pointed ends.

'7. In apparatus for producing spikes or the like the combination ofthree axially spaced induction heating coils to heat the end portionsand the center portion of a length of stock, means to grip said stocklength at points intermediate the centrally heated portion thereof andthe heated end portions thereof, means to upset the ends of said stocklength, and means to move said gripping means away from each otherwhereby said stock length will be pulled apart at said centrally heatedportion.

8. In apparatus for producing spikes or the like each having an upsethead the combination of means to feed predetermined and uniform lengthsof stock in step-by-step progression and axially along a predeterminedpath, means adjacent said path to heat said stock lengths only at theirend portions and at their center portions upon said stock piecesreaching a predetermined advanced position along said path, and means atthe end of said path to simultaneously upset both ends of eachsucceeding stock length and to thereafter sever each succeeding stocklength at the centrally heated portions thereof thus producing twocomplete spikes or the like from each length of stock.

9. In apparatus for producing spikes or the like the combination ofmeans to feed successive lengths of stock in step-by-step axialprogression, three induction heating coils mounted to encompass the endportions and the center portion of each succeeding length of stock asthe same reaches a predetermined station alon its path of travel, andmeans spaced further along the path of travel of said stock lengths toupset the ends of said lengths and to sever said lengths at saidcentrally heated portions to produce two headed spikes or the like fromeach length of stock.

10. In apparatus for producing spikes or the like from an elongatedblank heated at its end and center portions the combination of means toelevate said blank from a lower horizontal position to an upperhorizontal position, means to grip said blank at its cooler portionsintermediateits center and end portions when in said upper position,means to upset the ends of said blank while the blank is so gripped toform spike heads, and means to swage the centrally heated portion ofsaid blank and to move said gripping means apart whereby said blank issevered to produce two spikes each having a headed end and a pointedend.

11. In apparatus for producing spikes or the like the combination ofmeans to elevate an elongated blank heated at its end and centerportions from a lower horizontal position to an upper horizontalposition, an electromagnet having spaced pole pieces to engage saidblank at its cooler portions to retain said blank in upper position uponretraction of said elevating means, means to grip the opposite endportions of said blank when in upper position, a pair of swaging diesfor upsetting the ends of said blank while the blank is so gripped, andmeans to swage the centrally heated portion of said blank and to movesaid gripping means apart whereby said blank is formed and severed intotwo spikes each having an upset head and a pointed end.

12. In apparatus of the character described a pair of spaced parallelshafts coupled for simultaneous driven rotation, a pair-of spacedparallel struts mounted on said shafts andslideable axially along saidshafts for movement toward and away from each other, cam means on saidshafts for moving said struts toward and away from each other, andclamping means on said struts operative upon rotation of said shafts toclamp the opposite ends of an elongated work blank, the arrangementsbeing such that said cam means is operative to move said struts apartwhile said clamping means grips the opposite ends of said blank.

13. Apparatus according to claim 12 further including swaging means toupset the ends of said blank while the same is secured in said clamps,and timing means to actuate said swaging means before said cam means isoperative to move said struts apart.

14. In apparatus of the character described the combination of a crankshaft and two cam shafts mounted for rotation about spaced parallelaxes, power means to rotate said shafts in unison, means to feed anelongated blank into a position substantially between and parellel withsaid cam shafts, a pair of struts spanning said cam shafts and slideablethereon axially of said shafts, clamping means on said struts forgripping opposite ends of said blank upon predetermined rotation of saidcam shafts, swaging means coupled with said crank shaft to upset theends of said blank while the same is held in said clamping means,swaging means operated by said cam shafts to flatten the center portionof said blank while the blank is held in said clamping means, and cammeans on said cam shafts to move said sturts apart after actuation ofsaid first and second mentioned swagin means.

15. Apparatus according to claim 14 further including means operativeupon continued rotation of said cam shafts to open said clamping meansfollowing actuation of said means to move said struts apart and tothereafter move said struts to their initial adjacent startingpositions.

16. Apparatus according to claim 15 further including automatic means toelevate a horizontally disposed blank into position between said openedclamping means when said struts are in their initial adjacent positions.

17. In apparatus of the character described the combination of a frame,a pair of spaced parallel shafts journaled on said frame, a saddlemounted on said frame and extending transversely above said shafts, apair of spaced parallel struts mounted on said shafts in spanningrelation therewith and slideable axially along said shafts for movementtoward and away from each other, 10

said saddle being disposed intermediate and above said struts, means onsaid struts operative upon rotation of said shafts to clamp the endportions of an elongated blank, cam means on said shafts cooperatingwith cam following means on said struts to move said struts toward andaway from each other upon continued rotation of said shafts, swageblocks slideably mounted on the underside of said saddle for movementtoward and away from each other to reduce the thickness of a blank heldin said clamping means, and cam means on said shafts coupled with saidswage blocks to move said swage blocks toward and away from each other.

18. Apparatus accordin to claim 17 further 16 including means operativesynchronously with said shafts to upset the ends of said blank while thesame is held in said clamping means.

IRWIN ROPP. WILBERT S. BLACKSTONE.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 396,014 Thomson Jan. 8, 1889483,424 Coffin Sept. 27, 1892 1,341,626 Kobert May 25, 1920 1,341,808 LaPotterie June 1, 1920 1,344,961 Remington June 29, 1920 1,417,806 LaPotterie May 30, 1922 1,755,323 Herron Apr. 22, 1930 1,867,936 BenedettoJuly 19, 1932 1,873,619 Mojonnier Aug. 23, 1932 1,998,363 Frost Apr. 16,1935 2,195,775 Gaspar Apr. 2, 1940 2,275,763 Howard Mar. 10, 1942

